Sway Brace Attachment

ABSTRACT

A sway brace attachment for firmly connecting to a beam and other flanged structures, and a method for manufacturing the sway brace attachment. The sway brace attachment includes a main body and an insert that is captured within the main body by a pair of set screws which also engage the flange. Preferably, a third set screw is supported by the main body and engages the opposite side of the flange from the pair of set screws. The main body can be generally rectangular in shape, with a top wall, a pair of side walls extending from the top wall and a pair of bottom walls, which extend inwardly from respective side walls in an overlapping relationship. The sway brace attachment can be used for bracing pipes and other loads, suspended below ceilings and floors, against sway and seismic disturbances.

PRIORITY DATA

This application is a continuation application and claims the benefit ofU.S. patent application Ser. No. 13/149,779, filed May 31, 2011, whichis incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to devices for bracing pipes and otherloads, suspended below floors and ceilings, against sway and seismicdisturbances, and, in particular, to a sway brace attachment for firmlygripping a building support, such as a beam, and other flangedstructures.

2. Description of the Related Art

There is a multitude of products in the market utilized by building andplumbing contractors for bracing and supporting pipes, ducts, sprinklersystems, fans, air-conditioners and other loads below floors andceilings. These products include clamps, braces, hooks, straps, plates,brackets, among other items. Typically, one end of a brace is attachedto the load while the other end is attached to a beam, or other supportstructure, on a floor or a ceiling. Due to the variety of possible beamtypes, sizes and orientations, as well as the variety of loads that needto be braced, the mechanism that attaches the brace to the beam shouldhave a high load capacity and be capable of mounting on various types,sizes and locations of a flange.

Although such attachment mechanisms exist, including sway braceattachments sold by Tolco, a brand of Nibco, Inc., the assignee of thepresent application, a demand exists for sway brace attachments havingequivalent or improved performance relative to existing attachments.Thus, there is a need for a sway brace attachment which can not onlywithstand substantial loads, but is also simply and expeditiouslyinstallable and adjustable, and is preferably economical to manufacture,thereby being desirably inexpensive in cost and in use.

SUMMARY OF THE INVENTION

A sway brace attachment constructed in accordance with one or moreembodiments of the present invention incorporates a main body with aninsert, or locking bar, and one or more set screws or other means forfirmly connecting the sway brace attachment to a flange, such as thatformed by beam, or other suitable structure. The sway brace attachmentis part of a bracing system which is used to prevent swaying of pipesand other loads suspended below ceilings and floors. The sway braceattachment firmly grips a flange and is, typically, attached to one endof a brace while the other end of the brace is connected to the load.

Advantageously, the preferred sway brace attachments can not onlywithstand substantially heavy loads and is economical to manufacture,but it can also be used to support and/or suspend a wide variety ofloads below ceilings and floors and further it can be attached tobasically any flanged structure, for example, I-beams, H-beams, channelsand plates among others, or any structure offering a relatively thin,flat surface for clamping.

An embodiment involves a sway brace attachment for clamping to a flangeof a beam or other support structure. The sway brace attachment includesa body having a pair of spaced, generally parallel side walls, with eachof the side walls having an elongated slot. Each of the slots has aclosed end and an open end opening to one edge of a respective one ofthe side walls, with each of the slots opening in the same direction.Each of the slots has a first portion and a second portion. The firstportions of the slots are configured to receive the flange. The bodyalso includes a pair of overlapping walls, with one of the overlappingwalls connected to one of the side walls and the other of theoverlapping walls connected to the other of the side walls. Theoverlapping walls each having aligned holes passing therethrough, withat least one of the aligned holes being threaded. An insert extendsbetween the side walls and is generally perpendicular thereto. Theinsert has one end extending through the second portion of the slot ofone of the side walls and supported by the one side wall. The insert hasan opposite end extending through the second portion of the slot of theother side wall and supported by the other side wall. The insert has atleast one threaded hole and at least one first set screw extends throughthe at least one threaded hole of the insert to engage a first surfaceof the flange in the slots. A second set screw extends through thealigned holes of the overlapping walls to engage a second surface of theflange opposite the first surface. The at least one first set screw andthe second set screw cooperate to connect the sway brace attachment tothe flange.

In some arrangements, the at least one threaded hole of the insert canbe a pair of spaced threaded holes, each adjacent a respective one ofthe side walls, and the at least one first set screw can be a pair ofset screws respectively extending through the threaded holes of theinsert to engage the flange.

In some arrangements, the body can also include a top wall extendingbetween the side walls, with the top wall including at least one openingaligned with the at least one threaded hole and in which the at leastone first set screw passes through the at least one opening of the topwall. The at least one threaded hole of the insert can be a pair ofspaced threaded holes each adjacent a respective one of the side wallsand the at least one opening of the top wall can be a pair of spacedopenings aligned with a respective one of the spaced threaded holes, Theat least one first set screw can be a pair of set screws respectivelyextending through the respective spaced openings and the respectivethreaded holes of the insert to engage the flange.

In some arrangements, the sway brace attachment includes a nut that isengagable with the second set screw for coupling the sway braceattachment to a load. The sway brace attachment can utilize set screwsthat each have a head configured to break off from a shaft portion whentightened to a threshold torque level. The closed end of each of theslots defined by the first portion can be offset from a portion of theclosed end defined by the second portion to create a shoulder upon whichthe insert can rest. In some cases, the overlapping walls overlap asubstantially entirely of one another.

An embodiment involves a sway brace attachment for clamping to a flangeof a beam or other support structure and includes a body having a topwall, a first side wall extending from a first edge of the top wall, asecond side wall extending from a second edge of the first wall oppositethe first edge, the second side wall extending in the same direction asthe first side wall, a first bottom wall extending from the first sidewall and a second bottom wall extending from the second side wall. Thefirst bottom wall and the second bottom wall overlap one another. Thetop wall has a pair of openings, the first bottom wall has a firstopening and the second bottom wall has a second opening. The firstopening is aligned with the second opening and at least one of the firstand second openings is threaded. The first side wall and the second sidewall include a first slot and a second slot, respectively, which arealigned with one another and configured to receive the flange. Each ofthe first and second slots has a closed end and an open end, wherein theopen ends face in the same direction. An insert extends between, and issupported by, the first side wall and the second side wall. The inserthas a first threaded hole and a second threaded hole, which are alignedwith a respective one of the pair of openings in the top wall. A firstset screw extends through one of the pair of openings in the top walland is threaded into the first threaded hole of the insert. A second setscrew extends through the other of the pair of openings in the top walland is threaded into the second threaded hole of the insert. A third setscrew extends through the respective first and second openings of thefirst and second bottom walls. The first, second and third set screwsare configured to contact the flange to secure the sway brace attachmentto the flange.

In some arrangements, the first slot and the second slot each has afirst portion and a second portion. The flange is received within therespective first portions of the first and second slots and the insertis received within the respective second portions of the first andsecond slots. In each of the first and second slots, a portion of theclosed end defined by the first portion can be offset from a portion ofthe closed end defined by the second portion to create a shoulder uponwhich the insert can rest. In some cases, a substantial entirety of thefirst bottom wall and the second bottom wall overlap one another. A nutcan be provided that is engagable with the third set screw for couplingthe sway brace attachment to a load. One or more of the first set screw,second set screw and the third set screw can have a head configured tobreak off from a shaft portion when tightened to a threshold torquelevel. The pair of openings of the top wall can be spaced in a lateraldirection from one another such that one opening is adjacent the firstside wall and the other opening is adjacent the second side wall. Thefirst, second and third set screws can be aligned with one another in alongitudinal direction of the sway brace attachment.

An embodiment involves a method of assembling a sway brace attachment toa flange, including sliding at least a pair of aligned slots formed by amain body of the sway brace attachment onto the flange. A first setscrew and a second set screw are threaded through a respective one of apair of threaded holes disposed in an insert of the sway braceattachment until ends of the set screws engage a first side of theflange. A third set screw is threaded through a threaded hole disposedin the main body until an end of the third set screw engages a secondside of the flange opposite the first side.

In some methods, the third set screw is passed through a pair ofoverlapping walls of the main body, and at least one of the overlappingwalls defines the threaded hole of the main body. In some methods, thefirst, second and third set screws are tightened until a head portion ofeach set screw breaks off from a shaft portion of each set screw. Insome methods, a nut is removed from the shaft portion of the third setscrew after the head is broken off from the shaft, a sway brace ispositioned onto the shaft portion of the third set screw and the nut isreplaced onto the third set screw to couple the sway brace to the swaybrace attachment.

An embodiment also involves a method of making a main body of a swaybrace attachment including stamping a flat, generally rectangular workpiece, bending side walls relative to a top wall and bending first andsecond bottom walls relative to the side walls such that the bottomwalls overlap one another. The stamping preferably includes creatingslots in the side walls configured to receive a flange, at least onehole (preferably, two spaced holes) in the top wall and aligned holes inthe bottom walls. The creation of the slots can also include creatingportions to receive an insert. The portions created to receive theinsert can be offset from the remaining portion(s) of the slots tocreate a shoulder, which can support the insert. One of the alignedholes in the bottom walls can be threaded. An embodiment also includespre-assembling the sway brace attachment by inserting the insert intothe slots, passing a set screw(s) into each of the at least one hole andthreading the set screw(s) into corresponding threaded holes of theinsert to couple the insert to the main body. Another set screw can havea nut screwed onto it and can then be threaded into the aligned holes.

For purposes of summarizing the invention and the advantages achievedover the prior art, certain objects and advantages of the invention havebeen described herein above. Of course, it is to be understood that notnecessarily all such objects and advantages may be achieved inaccordance with any particular embodiment of the invention. Thus, forexample, those skilled in the art will recognize that the invention maybe embodied or carried out in a manner that achieves or optimizes oneadvantage or group of advantages as taught herein without necessarilyachieving other advantages as may be taught or suggested herein. All ofthese embodiments are intended to be within the scope of the inventionherein disclosed. These and other embodiments of the present inventionwill become readily apparent to those skilled in the art from thefollowing detailed description of the preferred embodiments havingreference to the attached figures, the invention not being limited toany particular preferred embodiment(s) disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the presentinvention are described herein with reference to drawings of a preferredembodiment, which is provided for the purpose of illustration, and notlimitation. The drawings contain eight (8) figures.

FIG. 1 is a perspective view of a bracing system attached to a beam andutilized to brace a load, such as a pipe. The bracing systemincorporates a sway brace attachment having certain features, aspectsand advantages of the present invention. The sway brace attachmentcouples a sway brace assembly to the beam.

FIG. 2 is a perspective view of the sway brace attachment of FIG. 1separate from the bracing system, which includes a main body, an insertand a plurality of set screws.

FIG. 3 is a side view of the sway brace attachment of FIG. 1.

FIG. 4 is a front view of the sway brace attachment of FIG. 1.

FIG. 5 is a cross-sectional view of the insert of the sway braceattachment of FIG. 1 separate from the sway brace attachment and takenalong the line 5-5 of FIG. 6.

FIG. 6 is a top view of the insert of FIG. 5.

FIG. 7 is a side view of the set screw of the sway brace attachment ofFIG. 1 separate from the sway brace attachment.

FIG. 8 is a plan view of a work piece that can be bent to create themain body of the sway brace attachment of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1-7 show a sway brace attachment 10, and various componentportions of the attachment 10, constructed and assembled in accordancewith certain features, aspects and advantages of an embodiment of theinvention. FIG. 1 illustrates the sway brace attachment 10 attached to astructural or support member 12 and utilized to support a supportedmember 14. The illustrated support member 12 is an I-beam; however, thesway brace attachment 10 can be utilized with other types of beams,flanged members and other support members including, for example, wideflange beams, open web and welded truss beams, C-channel, metal trusses,structural steel and the like. The illustrated supported member 14 is apipe that is generally perpendicular with respect to the beam 12. Thesupported member 14 can also be a pipe that is generally parallel to thebeam 12 or that runs at an oblique angle relative to the beam 12. Thatis, the sway brace attachment 10 can be a lateral or longitudinal swaybrace. Moreover, the supported member 14 can be any kind of pipe,ducting, electrical conduit or any other member for which bracing isdesired.

The sway brace attachment 10 can be coupled to the supported member 14through one or more intermediate structures, such as a sway brace orsway brace assembly 16. In the illustrated arrangement, a modular systemis used in which a transitional element 18 is coupled to the sway braceattachment 10 and a bracing pipe 20 is coupled to the transitionalelement 18. However, in other arrangements, the sway brace can be asingle structure, which may be rigid or adjustable. The supported member14 is coupled to the bracing pipe 20 through a hanger attachment or“braced-pipe” attachment 22, such as a pipe hanger. The pipe hanger orhanger attachment 22 can be of any suitable construction depending onthe object to be supported. The pipe or other supported member 14 whichis supported by the bracing pipe 20 can be referred to as the “bracedpipe” or “braced member.”

The illustrated sway brace attachment 10 comprises a main body 30, aninsert 32 and one or more threaded fasteners 34. In the illustratedarrangement, the main body 30, the insert 32 and the threaded fasteners34 are all separate components from one another. However, otherconfigurations also are possible. The insert 32 cooperates with the mainbody 30 to support one or more of the threaded fasteners 34. Inparticular, preferably, the insert 32 receives two of the threadedfasteners 34 and transfers a load from the fasteners 34 to the main body30. Preferably, a third fastener 34 is received by the main body 30. Thefasteners 34 secure the main body 30 to the beam or other support member12 thereby preferably providing a multiple point (e.g., a three point)mechanical connection between the sway brace attachment 10 and the beam.The upper and lower fasteners 34 can be aligned with one another inlongitudinal and/or lateral directions of the sway brace attachment 10,or the fasteners 34 can be offset from one another. For example, theupper fasteners 34 can be offset from the lower fastener(s) 34 in thelongitudinal and/or lateral direction. However, preferably, the upperand lower fasteners 34 are aligned in the longitudinal direction andoffset in the lateral direction, with a single lower fastener 34positioned between the pair of upper fasteners 34.

With additional reference to FIGS. 2-4, the main body 30 generallycomprises a top wall 40. The main body 30 also comprises a first sidewall 42 and a second side wall 44. The first side wall 42 extendsdownward from the top wall 40 and the second side wall 44 extendsdownward from the top wall 40. The first and second side walls 42, 44can be mirror images of one another. A first bottom wall 46 extendsinwardly from a lower portion of the first side wall 42 and a secondbottom wall 48 also extends inwardly from a lower portion of the secondside wall 44. The illustrated main body 30 is hollow and generallyrectangular in cross-sectional shape. Preferably, the first bottom wall46 and second bottom wall 48 overlap one another along a substantialportion thereof. In the illustrated arrangement, the first bottom wall46 and second bottom wall 48 overlap one another over a substantialentirety of their length, that is, in the width direction of the swaybrace attachment 10.

The terms “top,” “bottom,” “side” and the like are merely used toprovide a frame of reference for this written description. Thestructures described herein can be mounted in any particular orientationand, therefore, the usage of these terms should not be consideredlimiting in any manner. Other relative or directional terms may be usedherein. These terms are used in the context of the particularorientation(s) shown and should not be considered as limiting thestructures to the illustrated orientation in actual use.

Preferably, the main body 30 is formed from a single plate 50 ofmaterial (FIG. 8). In other words, the main body 30 preferably is formedas a monolith or single structure and each of the walls 40, 42, 44, 46,48 is integrally related. Stated yet another way, each of the adjoiningwalls (e.g., the top wall 40 and the first side wall 42) is connected ata bend. Other configurations are possible; however, the integratedconstruction advantageously reduces time and complication duringmanufacture.

The first side wall 42 has an elongated first slot 52 extending throughan edge 54 of the first side wall 42. Similarly, the second side wall 44has an elongated second slot 56 extending through an edge 58 of thesecond side wall 44. The slots 52 and 56 preferably are aligned in avertical direction and open in the same direction such that the mainbody 30 defines a jaw-like shape with a mouth configured to receive aflange of a beam or a portion of a support member 12, for example, asshown in FIG. 1. Preferably, the slots 52 and 56 generally define anL-shape or J-shape when viewed from the side. A first, preferablyrectangular, portion 60 of each of the slots 52 and 56 is configured toreceive the flange of the beam or a portion of another support member12. Preferably, the first rectangular portion 60 has a height that isequivalent or substantially equivalent to the height of the opening inthe respective edge 54, 58. The mouth or jaw is sized and shaped to fitrelatively thick flanges, which improves the versatility of theattachment 10.

The side walls 42 and 44 each define a second, preferably rectangular,portion 62 of each respective slot 52 and 56 that is above, andpreferably adjacent, the first portion 60. That is, preferably, thesecond portion 62 opens into the first portion 60 of each slot 52 and56. Preferably, a rearward end of the second portion 62 is spaced in arearward direction from a rearward end of the first portion 60. Thus, asupport surface or shoulder 64 is defined at a juncture between thefirst portion 60 and second portion 62 of each slot 52 and 56.Preferably, the second portions 62 of each slot 52 and 56 are alignedand sized to receive the insert 32. Thus, preferably, a portion of theinsert 32 can rest on the shoulder 64 when assembled. Although it ispreferred that the first portion 60 and second portion 62 are formed asportions of a single slot 52 or 56 for efficiency in manufacturing andassembly of the sway brace attachment 10, other arrangements are alsopossible in which the first portion 60 and second portion 62 are eachformed by separate slots or openings.

The top wall 40 has a pair of holes 68, 70 which are preferably alignedwith one another and aligned with the second portion 62 of each slot 52and 56 in a forward-rearward direction. In particular, preferably, theholes 68, 70 are substantially aligned with a center line of the secondportion 62 of the slots 52, 56. The holes 68, 70 are sized toaccommodate the fasteners 34 and, preferably, are somewhat, but notsubstantially, larger than the outer diameter of the shaft portion ofthe fasteners 34. Thus, the holes 68, 70 limit radial movement of thefasteners 34. Preferably, the holes 68, 70 are defined by relativelysmooth walls. That is, preferably, the holes 68, 70 are not threaded.

The insert 32, which can be referred to as a locking bar, (see FIGS. 5and 6) preferably is generally elongated and rectangular with a firstend 72 positioned in the second portion 62 of the slot 52, and a secondend 74 positioned in the second portion 62 of the slot 56. The ends 72,74 have a generally rectangular perimeter. The insert 32 is in agenerally perpendicular relation to the side walls 42, 44 and partiallyrests on the shoulder 64. The insert 32 has one or more threaded holesto accommodate the threaded fasteners 34. Preferably, the insert 32 hasa pair of threaded holes 76 and 78 adjacent to the side walls 42 and 44,respectively, and are aligned with the holes 68 and 70, respectively,when the insert 32 is positioned in the main body 30. Thus, the threadedfasteners 34 preferably pass through a respective one of the holes 68,70 and threadably engage a respective one of the threaded holes 76, 78.With the insert 32 partially resting on the shoulder 64, the threadedfasteners 34 engaging the insert 32 and the holes 68, 70 of the mainbody 30 inhibiting substantial movement of the threaded fasteners 34,the insert 32 preferably is held in place within the second portions 62of the slots 52, 56. That is, the interaction between the threadedfasteners 34 and the holes 68, 70 restricts a forward end of the insert32 from rotating in a downward direction, thereby inhibiting removal ofthe insert 32 from the second portions 62 of the slots 52, 56.Conveniently, the insert 32 is held in place even with the threadedfasteners 34 backed off to ease assembly of the sway brace attachment 10to a support member, as described further herein.

Preferably, the first bottom wall 46 has a first opening 80 and thesecond bottom wall 48 has a second opening 82 that are aligned with oneanother. In the illustrated arrangement, the first opening 80 and thesecond opening 82 are also aligned in a forward-rearward direction withthe openings 68, 70 of the top wall 40. Preferably, the openings 80, 82are centered or substantially centered in a width direction of the mainbody 30. The first opening 80 and the second opening 82 are configuredto accommodate a threaded fastener 34. Preferably, one of the firstopening 80 and the second opening 82 is threaded and the other of thefirst opening 80 and the second opening 82 is not threaded. In theillustrated arrangement, the first opening 80 of the first bottom wall46 (i.e., the relative upper one of the bottom walls 46, 48) is threadedand the second opening 82 of the second bottom wall 48 (i.e., therelative lower one of the bottom walls 46, 48) is not threaded or isunthreaded. However, in other arrangements, this order could be reversedor both openings 80, 82 could be threaded. The presence of the threadedfastener 34 within the openings 80, 82 inhibits or prevents significantrelative movement between the first bottom wall 46 and the second bottomwall 48. In particular, lateral movement of the bottom walls 46, 48 isinhibited or substantially prevented to inhibit or substantially preventspreading of the bottom walls 46, 48 and side walls 42, 44 of the mainbody 30, thereby maintaining the strength of the sway brace attachment10. Thus, preferably, the unthreaded opening 80 or 82 (if any) is sizedrelatively closely to the outside diameter of the shaft portion of thefastener 34. Although the fastener 34 may be provided as a means ofcoupling the bottom walls 46, 48 to inhibit or at least substantiallyprevent spreading of the bottom walls 46, 48, other suitable mechanismscan also be used for this purpose, including fasteners (e.g., rivets,screws) that do not contact the flange, clamps, welding, interferencestructures and other suitable arrangements for fixing the bottom walls46, 48 relative to one another.

In the illustrated arrangement, the lower threaded fastener 34 (i.e.,the threaded fastener passing through the lower walls 46, 48) includes anut 90 (FIGS. 1 and 2) threadably engaging a threaded shaft portion ofthe fastener 34. The nut 90 can be used to secure a sway brace assembly16 (FIG. 1) to the sway brace attachment 10, as described furtherherein.

Preferably, the main body 30 and the insert, or locking bar, 32 arefabricated from hot-rolled, low-carbon steel to meet the standards setby the Underwriters Laboratories (U.L.), Factory Mutual Engineering(F.M.), or other such quality control groups, though other suitablematerials may also be used. Additionally, the main body 30 and theinsert 32 may have a plain or electro-galvanized finish.

With reference to FIG. 7, an embodiment of a threaded fastener 34 isshown. The threaded fasteners 34 may also be referred to herein as setscrews. Preferably, each threaded fastener 34 has a head portion 92 anda threaded portion 94. As described, two of the set screws 34 extendthrough the holes 68 and 70, respectively, and are threaded into theholes 76 and 78 of the insert 32, thereby capturing the insert 32 withinthe slots 52, 56. The set screws 34 are long enough to be threadedthrough the insert 32 to engage a flange, or other structure, positionedin the slots 52, 56. Another set screw 34 preferably extends through theholes 80 and 82 of the lower walls 46 and 48, respectively. This setscrew 34 is long enough to engage the flange, or other structure,positioned in the slots 52, 56. Each of the set screws 34 has an end 96,which preferably is in the form of a relatively sharp cone point forengaging the flange, or other structure. The cone point 96 facilitatesthe set screws 34 in creating a deformation in the flange, or otherstructure, to increase the bite of the set screw 34 in the flange, orother structure, to inhibit or prevent sliding movement of the set screw34. The cone point 96 does not necessarily need to possess a sharppoint. A small flat surface at the end can be permissible. Preferably,any flat surface at the end 96 is less than about 0.05 inches, less thanabout 0.04 inches or less than about 0.031 inches. In otherarrangements, the end 96 can be a cup point or other type of endstructure, if needed or desired.

Preferably, the screw head 92 is adapted to break off at a particulartorque level or particular torque range, which may be a threshold orpredetermined torque level or range. This feature is a convenient methodfor ensuring that the set screw 34 has been properly torqued ortightened. As illustrated, a portion of the shaft of the set screw 34includes a reduced cross-section portion 98. The reduced cross-sectionportion 98 can have a particular minimum diameter (or cross-sectionaldimension for non-circular shapes) selected in view of the materialproperties, heat treatment and/or other relevant factors such that thescrew head 92 will break off at a particular torque level, which may bea particular minimum value or a range of values.

In the illustrated embodiment, the main body 30 is about 0.25 inchesthick. The overall peak dimensions of the main body 30 are about 3.5inches high, 2.375 inches wide, and 3 inches long. The top wall 40 ispreferably about 2.375 inches wide and spaces the inner surfaces of theside walls 42 and 44 by about 1.875 inches. The side walls 42 and 44preferably have a peak height of about 3.5 inches. The first portions 60of the slots 52 and 56 have dimensions of about 1.5 inches by about 0.9inches (length by height). With such dimensions, the sway braceattachment 10 is capable of use with flanges between about ⅜ inch and ⅞inch thickness. The second portions 62 of the slots 52 and 56 havedimensions of about 1.031 inches by about 0.39 inches (length byheight). The rearward ends of the first portions 60 and second portions62 are offset from one another such that the shoulder 64 has a length ofabout 0.156 inches. The top wall 40 and upper portions of the side walls42, 44 above the slots 52, 56 have a length (in a forward-rearwarddirection) of about 2.75 inches. The bottom walls 46, 48 and lowerportions of the side walls 42, 44 below the slots 52, 56 have lengths ofabout 3 inches. Thus, the upper portions of the edges 54, 58 of the sidewalls 42, 44 above the slots 52, 56 are offset in a rearward directionfrom the lower portions of the edges 54, 58 of the side walls 42, 44below the slots 52, 56 by a distance of about 0.25 inches in aforward-rearward direction. The lengths of the first portions 60 of theslots 52, 56 are measured from the lower portions of the edges 54, 58.The upper bottom wall 46 has a width of about 1.841 inches and a lengthof about 3 inches. The lower bottom wall 48 has a width of about 1.966inches and a length of about 3 inches. A vertical gap between the upperbottom wall 46 and the lower bottom wall 48 is about 0.063 inches. Theholes 68, 70 have diameters of about 0.531 inches. The centers of theholes 68, 70 are spaced about 0.891 inches rearward of the forward edgeof the top wall 40, about 1.313 inches from one another and about 0.531inches from the side edges of the top wall 40. The centers of the holes80 and 82 are spaced about 1.141 inches from the front edges of thebottom walls 46, 48 and substantially centered in the lateral directionof the walls 46, 48 and/or along the center line of the main body 30.The threaded hole 80 has a diameter of about 0.5 inches and theunthreaded hole 82 has a diameter of about 0.563 inches.

Preferably, the insert 32 (see FIGS. 2 and 3) is about 0.375 inchesthick, about 1 inch wide (forward-rearward or length direction of theassembled sway brace attachment 10) and about 2.5 inches in length(lateral or width direction of the assembled sway brace attachment 10),which permits it to fit comfortably in the second portions 62 of theslots 52, 56 and slightly extend outwardly side walls 42, 44 when theinsert 32 is placed in the main body 30. The spacing between thethreaded holes 76 and 78 is preferably about 1.313 inches, whichdisposes them in substantial alignment with the holes 68 and 70,respectively. The threaded holes 76, 78 comprise standard ½-inch femalethreads.

Preferably, with reference to FIG. 7, the threaded portion 94 of eachset screw 34 comprises standard ½-inch threads. The shaft portion of theset screw 34, including the threaded portion 94, end 96 and reducedcross-section portion 98 preferably is about 2.5 inches in length, sothat the cone point 96 can extend into the area defined between theslots 52 and 56. The reduced cross-sectional portion 98 can have alength of about 0.188 inches. Preferably, the set screws 34 arefabricated from a hardened carbon steel, though other suitable materialsmay be used. Of course, those skilled in the art will recognize thatthese and other dimensions presented herein are illustrative of onepreferred embodiment, and that the present invention may bealternatively dimensioned with efficacy, as required or desired.

The present invention also prescribes a method for attaching the clampor sway brace attachment 10 to a flange or other support structure. Themethod preferably begins with sliding slots 52 and 56 of the sway braceattachment 10 over the flange, for example, the bottom flange of thebeam 12, as shown in FIG. 1. The upper set screws 34 (i.e., the setscrews that engage the insert 32) are inserted through respective holes68 and 70 in the main body 30 and threaded into holes 76 and 78 in theinsert 32 until the cone points 96 of the set screws 34 make contactwith the flange. The set screws 34 are tightened preferably until theirheads 92 break off, whereby the set screws 34 securely contact theflange. Preferably after the upper set screws 34 are properly tightened,the lower set screw 34 (i.e., the set screw that engages the main body30) is tightened against the flange preferably until its head 92 breaksoff This procedure results in the sway brace attachment 10 being firmlyattached to the flange 60. As described, the provision of upper andlower set screws 34 increases the bite of the sway brace attachment 10on the flange to increase resistance to overturning (rotation) of thesway brace attachment 10.

Thus, it can be seen that the set screws 34 comprise means extendingbetween the insert 32 and the flange that connect the sway braceattachment 10 to the flange. If desired, means other than set screws maybe employed to provide the necessary function. For example, this meanscan comprise a suitable wedge, such as a spring-loaded and/or cammedmember, operable via a lever or the like and extending between theinsert 32 and the flange. The means reacts against the insert 32 andpresses the flange against the portions of the side walls 42, 44 formingrespective bottom edges of the respective slots 52, 56.

In use, once the sway brace attachment 10 has been attached to the beam12, it may be used to support loads, for example, pipe 14. The beam 12may either support a floor or a ceiling with the floor or ceilingresting on the top horizontal flanges of the beam 12. Preferably, theslots 26 and 28 are dimensioned to easily slip over the flange of commonbeam sizes, as well as other common or suitable support structures.

The sway brace attachment 10 is capable of supporting substantiallylarge loads. In one embodiment, the maximum load rating is at leastabout 2000 pounds and, in particular, 2015 pounds. This is, in part, dueto the availability of the slot portions 62 in which the insert 32resides and the slot portions 60 in which the flange resides. In thismanner, the load is not only distributed over the main body 30, but theinsert 32 is also supported at two locations by the side walls 42, 44 ofthe main body 30, which resists bending and buckling of the insert 32.Advantageously, the placement of the set screws 34 ensures that theregions of high stress concentrations on the insert 32 are adjacent tosupport provided by the side walls 42, 44 of the main body 30. Moreover,the provision of two bottom walls 46, 48 and a set screw 34 passingthrough the bottom walls 46, 48 inhibits or at least substantiallyprevents spreading of the bottom walls 46, 48 (and, thus, the side walls42, 44) to create an effective closed or box-shaped main body 30, whichprovides improved strength relative to U-shaped bodies or other openstructures. Additionally, the particular materials and dimensions usedin the construction of the sway brace attachment 10 further add to itsability to support substantially heavy loads.

The sway brace attachment 10 of FIG. 1 illustrates one preferred way ofsupporting a pipe 14 that is oriented substantially perpendicular to thebeam 12. As described previously herein, a transitional element 18 isattached to the sway brace attachment 10. In particular, after the swaybrace attachment 10 is attached to the beam 12 and the head 92 of thelower set screw 34 has been broken off, the nut 90 can be removed fromthe threaded portion 94 of the set screw 34. Then, the transitionalelement 18 (or other sway brace assembly 16) can be secured to the swaybrace attachment 10 by passing the set screw 34 through an aperture ofthe transitional element 18 and replacing and tightening the nut 90. Thefitting or transitional element 18 is coupled to one end of a bracingpipe 20, which has its other end connected to the pipe 14 (or othersupported or braced member) by means of a clamping device or pipe hanger22. The illustrated sway brace attachment 10 is configured for use with900 series sway brace assemblies and components sold by Tolco.RTM., butin some arrangements may also be suitable for use with other Tolco.RTM.assemblies and components, among other possible products. Those skilledin the art will readily recognize that suitable fittings other than thepipe hanger 22 and braces other than the bracing pipe 20 may also beemployed in conjunction with the sway brace attachment 10. Of course,more than one sway brace attachment 10 can be used, at spaced locationsalong the beam 12 and/or on additional beams, to support the pipe 14along its length. The number of clamps needed and, hence, their spacingis dependent on the size and weight of the pipe to be supported orbraced. Moreover, the sway brace attachment 10 can also be used tosupport ducts, sprinkler systems, fans, air-conditioners and other loadswhich are mounted below floors and ceilings.

Though FIG. 1 illustrates the sway brace attachment 10 attached to ahorizontal flange of a beam 12, those of ordinary skill in the art willreadily recognize that the sway brace attachment 10 of the presentinvention can be mounted on a variety of structures. For example, thesway brace attachment 10 may be attached to I-beams, H-beams, channels,plates, other flanged structures and the like. This versatility,advantageously, further adds to the modular nature of the sway braceattachment 10.

The sway brace attachment 10 of the present invention may bemanufactured by machining, casting or forging, but a preferred method ofmanufacturing the sway brace attachment 10 includes stamping flat stripsof metal plate. Referring to FIG. 8, a strip of metal plate is stampedinto a generally flat, rectangular shaped piece 100. In FIG. 8, whatwill become the interior or inward-facing surface of the sway braceattachment 10 is shown. The stamping includes punching a pair ofelongated slots 52, 56 in respective side walls 42, 44 of the piece 100.The side walls 42, 44 are spaced by a top wall 40. The stamping furtherincludes punching a pair of holes 68 and 70, which are situated nearrespective junctions (lines) 102, 104 between the top wall 40 and therespective side walls 52, 56. The piece 100 further includes a firstbottom wall 46 and a second bottom wall 48, one of which is adjacent theside wall 42 and the other of which is adjacent the side wall 44. In theillustrated piece 100, the first bottom wall 46 is adjacent the sidewall 42 to create a junction (line) 106 therebetween. Similarly, thesecond bottom wall 48 is adjacent the side wall 44 to create a junction(line) 108 therebetween. The stamping further includes punching a hole80 in the first bottom wall 46 and punching a hole 82 in the secondbottom wall 48. If desired, the junctions (lines) 102, 104, 106, 108 canbe provided with a crease or indentation to facilitate bending of thepiece 100. The side walls 42, 44 are bent, preferably approximately 90degrees with respect to the top wall 40, along the lines marked 102 and104, respectively. The bottom walls 46, 48 are also bent inwardly ortoward one another, preferably approximately 90 degrees with respect tothe respective side walls 42, 44, along the lines marked 106 and 108,respectively. Thus, a generally box-shaped sway brace attachment 10 iscreated. The opening 80 of the first bottom wall 46 can be threaded,before or after the bending of the walls.

With reference to FIGS. 5 and 6, a strip of metal plate is stamped intoa generally rectangular bar 110. The bar 110 is sized and configured tofit within the second portions 62 of the slots 52, 56 of the respectiveside walls 42, 44. The stamping includes punching a pair of holes 76, 78through the bar 110 which are spaced a distance approximately equal tothe spacing between the holes 68 and 70 of the main body 30. The holes76 and 78 are threaded, thereby creating the insert or locking bar 32.

In a preferred method of assembling the sway brace attachment 10, theinsert 32 is inserted into the second portions 62 of the slots 52, 56 ofthe respective side walls 42, 44 so that the threaded holes 76, 78 ofthe insert 32 are aligned with the respective holes 68, 70 of the topwall 40 of the main body 30. Each one of a pair of set screws 34 areinserted through respective holes 68 and 70 of the main body 30 andthreaded into respective threaded holes 76 and 78 of the insert 32,thereby capturing the insert 32 in the main body 30. A nut 90 isthreaded onto another set screw 34 with the bottom of the nut 90 facingaway from the head 92 of the screw 34. The combination of the set screw34 and nut 90 is then threaded into the threaded hole 80 of the firstbottom wall 46.

The above-described method is especially suited for automated assemblylines, wherein stamping, punching and bending operations can beefficiently executed. The simplicity and speed of this manufacturingmethod results in an end-product that is economical to manufacture and,thus, is desirably inexpensive. Of course, alternatively, and asmentioned before, the components of the sway brace attachment 10 may bemachined or otherwise manufactured, but this process is more timeconsuming and, consequently, more expensive.

The utility and versatility of the present invention will be readilyapparent to those skilled in the art. The sway brace attachment of thepresent invention can not only withstand substantially heavy loads andsupport and/or suspend a variety of loads, but is also adaptable to avariety of flanged structures, is simply and expeditiously installable,is economical to manufacture and, hence, desirably inexpensive.

While the components and method of the present invention have beendescribed with a certain degree of particularity, it is manifest thatmany changes may be made in the specific designs, constructions andmethodology hereinabove described without departing from the spirit andscope of this disclosure. It is understood that the invention is notlimited to the embodiments set forth herein for purposes ofexemplification, but is to be defined only by a fair reading of theappended claims, including the full range of equivalency to which eachelement thereof is entitled.

1-24. (canceled)
 25. A sway brace attachment for clamping to a flange ofa beam or other support structure, comprising: a body having a pair ofspaced first and second side walls, with each of the first and secondside walls having an elongate slot, wherein each of the slots has aclosed end and an open end opening to one edge of a respective one ofthe first and second side walls, wherein each of the slots has a firstportion and a second portion, the first portions of the first and secondslots configured to receive the flange; an insert extending having afirst end portion received in the second portion of the slot of thefirst side wall, and an opposite second end portion received in thesecond portion of the slot of the second side wall, the insert having atleast one threaded hole sized and shaped to receive a threaded fastener.26. The sway brace attachment of claim 25, further comprising at leastone threaded fastener threaded in the at least one threaded hole, the atleast one fastener configured to facilitate securement of the sway braceattachment to the flange when the flange is received in the firstportions of the first and second slots.
 27. The sway brace attachment ofclaim 26, wherein the at least one threaded fastener comprises at leastone set screw extending through the at least one threaded hole of theinsert to engage a first surface of the flange when the flange isreceived in the first portions of the first and second slots.
 28. Thesway brace attachment of claim 26, wherein the body has a top wallextending between the first and second side walls, the top wall has atleast one top hole, wherein each of the at least one top hole isvertically aligned with one of the at least one threaded hole of theinsert.
 29. The sway brace attachment of claim 28, wherein the body hasa bottom wall extending between the first and second walls and generallyopposing the top wall.
 30. The sway brace attachment of claim 29,wherein the bottom wall has a bottom threaded hole sized and shaped toreceive a threaded fastener.
 31. The sway brace attachment of claim 30,further comprising at least one threaded fastener threaded in the bottomthreaded hole, the at least one fastener configured to facilitatesecurement of the sway brace attachment to the flange when the flange isreceived in the first portions of the first and second slots.
 32. Thesway brace attachment of claim 29, wherein the bottom wall includesfirst and second overlapping walls, wherein the first overlapping wallis connected to and extends from the first side wall and the secondoverlapping wall is connected to and extends from the second side wall.33. The sway brace attachment of claim 32, wherein first and secondoverlapping walls have aligned bottom holes sized and shaped to receivea fastener.
 34. The sway brace attachment of claim 33, wherein thebottom hole of the overlapping wall is threaded and configured tothreadably receive a fastener.
 35. The sway brace attachment of claim25, wherein the first and second side walls each define a shoulderconfigured to support the insert in the second portions of the first andsecond slots.
 36. The sway brace attachment of claim 35, wherein aportion of the closed end of each of the slots defined by the firstportion is offset from a portion of the closed end defined by the secondportion to define the shoulder of each of the first and second sidewalls.